LEXUS ES300 2005 Workshop Manual
Manufacturer: LEXUS, Model Year: 2005, Model line: ES300, Model: LEXUS ES300 2005Pages: 969, PDF Size: 24.08 MB
Page 51 of 969
- INTRODUCTIONHOW TO USE THIS AUTOMATIC TRANSAXLE REPAIR
MANUAL01-3
3 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
7. SI UNIT
(a) The UNITS given in this manual are primarily expressed according to the SI UNIT (International Sys-
tem of Unit), and alternately expressed in the metric system and in the English System.
Example:
Torque:
30 NVm (310 kgfVcm, 22 ftVlbf)
Page 52 of 969
0103B-07
Z11554
Seal Lock Adhesive 01-4
- INTRODUCTIONREPAIR INSTRUCTION FOR AUTOMATIC
TRANSAXLE REPAIR MANUAL
4 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
REPAIR INSTRUCTION FOR AUTOMATIC TRANSAXLE
REPAIR MANUAL
PRECAUTION
1. BASIC REPAIR HINT
(a) PRECOATED PARTS
(1) Precoated parts are bolts, nuts, etc. that are coated
with a seal lock adhesive at the factory.
(2) If a precoated part is retightened, loosened or
caused to move in any way, it must be recoated with
the specified adhesive.
(3) When reusing precoated parts, clean off the old
adhesive and dry with compressed air. Then apply
the specified seal lock adhesive to the bolt, nut or
threads.
NOTICE:
Do the torque checking with the lower limit value of the torque tolerance.
(4) Depending on the seal lock agent to apply, there may be a case where it is necessary to leave
it for a specified time until it hardens.
(b) GASKETS
When necessary, use a sealer on gaskets to prevent leaks.
(c) BOLTS, NUTS AND SCREWS
Carefully observe all specifications for bolt tightening torques. Always use a torque wrench.
Page 53 of 969
L1 L2L1 L2
D02612
L2 L1L2 L1
D01201
L2 L1L2 L1
D01202
- INTRODUCTIONREPAIR INSTRUCTION FOR AUTOMATIC
TRANSAXLE REPAIR MANUAL01-5
5 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(d) TORQUE WHEN USING EXTENSION TOOL WITH
TORQUE WRENCH
(1) In case of tightening by extending the entire length
of the torque wrench combined with SST or tool, if
you tighten until the reading of the torque wrench
reached the specified torque value, the actual
torque becomes excessive.
(2) In this text, only the specified torque is described.
In case of using SST or extension tool, find the read-
ing of the torque wrench by the formula.
(3) Formula T'=T x L2/(L1 + L2)
T'Reading of torque wrench {NVm (kgfVcm, ftVlbf)}
TTorque {NVm (kgfVcm, ftVlbf)}
L1Length of SST or tool (cm)
L2Length of torque wrench (cm)
Page 54 of 969
0103C-05
01-6- INTRODUCTIONTERMS FOR AUTOMATIC TRANSAXLE REPAIR
MANUAL
6 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
TERMS FOR AUTOMATIC TRANSAXLE REPAIR MANUAL
ABBREVIATIONS USED IN THIS MANUAL
AbbreviationsMeaning
ASSYAssembly
AT FAutomatic Transaxle Fluid
B3U/D Brake
C2Reverse Clutch
C3U/D Clutch
FIPGFormed In Place Gasket
O/DOverdrive
SSMSpecial Service Materials
SSTSpecial Service Tools
U/DUnderdrive
w/With
w/oWithout
1stFirst
2ndSecond
Page 55 of 969
0103D-09
- INTRODUCTIONTERMS FOR AUTOMATIC TRANSAXLE REPAIR
MANUAL01-7
7 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
GLOSSARY OF SAE AND TOYOTA TERMS
This glossary lists all SAE-J1930 terms and abbreviations used in this manual in compliance with SAE rec-
ommendations, as well as their Toyota equivalents.
SAE
ABBREVIATIONSSAE TERMSTOYOTA TERMS
( )--ABBREVIATIONS
A/CAir ConditioningAir Conditioner
ACLAir CleanerAir Cleaner
AIRSecondary Air InjectionAir Injection (AI)
APAccelerator Pedal-
B+Battery Positive Voltage+B, Battery Voltage
BAROBarometric Pressure-
CACCharge Air CoolerInter cooler
CARBCarburetorCarburetor
CFIContinuous Fuel Injection-
CKPCrankshaft PositionCrank Angle
CLClosed LoopClosed Loop
CMPCamshaft positionCam Angle
CPPClutch Pedal Position-
CTOXContinuous Trap Oxidizer-
CTPClosed Throttle Potion-
DFIDirect Fuel Injection (Diesel)Direct Injection (DI)
DIDistributor Ignition-
DLC1
DLC2
DLC3Data Link Connector 1
Data Link Connector 2
Data Link Connector 31: Check Connector
2: Total Diagnosis Communication Link (TDCL)
3: OBD II Diagnostic Connector
DTCDiagnostic Trouble CodeDiagnostic Code
DTMDiagnostic Test Mode-
ECLEngine Control Level-
ECMEngine Control ModuleEngine ECU (Electronic Control Unit)
ECTEngine Control TemperatureCoolant Temperature, Water Temperature (THW)
EEPROMElectrically Erasable Programmable Read Only
memoryElectrically Erasable Programmable Read Only memory
(EEPROM),
Erasable Programmable Read Only memory (EPROM)
EFEEarly Fuel EvaporationCold Mixture Heater (CMH), Heat Control Valve (HCV)
EGRExhaust Gas RecirculationExhaust Gas Recirculation (EGR)
EIElectronic IgnitionDistributorless Ignition (DI)
EMEngine ModificationEngine Modification (EM)
EPROMErasable Programmable Read Only MemoryProgrammable Read Only Memory (PROM)
EVAPEvaporative EmissionEvaporative Emission Control (EVAP)
FCFan Control-
FEEPROMFlash Electrically Erasable Programmable
Read Only Memory-
FEPROMFlash Erasable Programmable Read Only Memory-
FFFlexible Fuel-
FPFuel PumpFuel Pump
GENGeneratorAlternator
GNDGroundGround (GND)
HO2SHeated Oxygen SensorHeated Oxygen Sensor (HO2S)
IACIdol Air ControlIdol Speed Control (ISC)
IATIntake Air TemperatureIntake or Inlet Air Temperature
ICMIgnition Control Module-
IFIIndirect Fuel InjectionIndirect Injection
IFSInertia Fuel-Shutoff-
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01-8- INTRODUCTIONTERMS FOR AUTOMATIC TRANSAXLE REPAIR
MANUAL
8 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U) ISC
Idle Speed Control-
KSKnock SensorKnock Sensor
MAFMass Air FlowAir Flow Meter
MAPManifold Absolute PressureManifold Pressure
Intake Vacuum
MCMixture Control
Electric Bleed Air Control Valve (EBCV)
Mixture Control Valve (MCV)
Electric Air Control Valve (EACV)
MDPManifold Differential Pressure-
MFIMultiport Fuel InjectionElectronic Fuel Injection (EFI)
MILMalfunction Indicator LampCheck Engine Light
MSTManifold Surface temperature-
MVZManifold Vacuum Zone-
NVRAMNon-V olatile Random Access Memory-
O2SOxygen SensorOxygen Sensor, O2 Sensor (O2S)
OBDOn-Board DiagnosticOn-Board Diagnostic (OBD)
OCOxidation Catalytic ConverterOxidation Catalyst Converter (OC), CC0
OPOpen LoopOpen Loop
PAIRPulsed Secondary Air InjectionAir Suction (AS)
PCMPowertrain Control Module-
PNPPark/Neutral Position-
PROMProgrammable Read Only Memory-
PSPPower Steering Pressure-
PTOXPeriodic Trap OxidizerDiesel Particulate Filter (DPF)
Diesel Particulate Trap (DPT)
RAMRandom Access MemoryRandom Access Memory (RAM)
RMRelay Module-
ROMRead Only MemoryRead Only Memory (ROM)
RPMEngine SpeedEngine Speed
SCSuperchargerSupercharger
SCBSupercharger Bypass-
SFISequential Multiport Fuel InjectionElectronic Fuel Injection (EFI), Sequential Injection
SPLSmoke Puff Limiter-
SRIService Reminder Indicator-
SRTSystem Readiness Test-
STScan Tool-
TBThrottle BodyThrottle Body
TBIThrottle Body Fuel InjectionSingle Point Injection
Central Fuel Injection (Ci)
TCTurbochargerTurbocharger
TCCTorque Converter ClutchTorque Converter
TCMTransmission Control ModuleTransmission ECU (Electronic Control Unit)
TPThrottle PositionThrottle Position
TRTransmission Range-
TVVThermal Vacuum ValveBimetallic Vacuum Switching Valve (BVSV)
Thermostatic Vacuum Switching Valve (TVSV)
TWCThree-W ay Catalytic ConverterThree-W ay Catalytic (TWC)
CC
RO
TWC+OCThree-W ay + Oxidation Catalytic ConverterCCR + CCO
VA FVolume Air FlowAir Flow Meter
VRVoltage RegulatorVoltage Regulator
VSSVehicle Speed SensorVehicle Speed Sensor (Read Switch Type)
WOTWide Open ThrottleFull Throttle
Page 57 of 969
- INTRODUCTIONTERMS FOR AUTOMATIC TRANSAXLE REPAIR
MANUAL01-9
9 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U) WU-OC
Warm Up Oxidation Catalytic Converter-
WU-TWCWarm Up Three-Way Catalytic ConverterManifold Converter
3GRThird Gear-
4GRFourth Gear-
Page 58 of 969
022FX-01
- PREPARATIONAUTOMATIC TRANSMISSION / TRANS
02-1
10 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
AUTOMATIC TRANSMISSION / TRANS
PREPARATION
SST
09214-7601 1Crankshaft Pulley ReplacerFRONT DIFFERENTIAL
ASSY(U151F)
09215-00013Crankshaft Bearing Remover &
Replacer Set BFRONT DIFFERENTIAL
ASSY(U151E)
(09215-00471)Camshaft Bearing Remover &
ReplacerFRONT DIFFERENTIAL
ASSY(U151E)
09223-15020Oil Seal & Bearing ReplacerFRONT DIFFERENTIAL
ASSY(U151E)
FRONT DIFFERENTIAL
ASSY(U151F)
09223-15030Oil Seal & Bearing ReplacerAUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
09308-00010Oil Seal PullerFRONT DIFFERENTIAL
ASSY(U151E)
OIL PUMP ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)
09316-12010Transfer Bearing ReplacerFRONT DIFFERENTIAL
ASSY(U151E)
09316-2001 1Transfer Bearing ReplacerUNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)
09350-32014TOYOTA Automatic Transmission
Tool SetOIL PUMP ASSY(U151E/U151F)
UNDERDRIVE CLUTCH
ASSY(U151E/U151F)
(09351-32070)No.2 Piston Spring CompressorUNDERDRIVE CLUTCH
ASSY(U151E/U151F)
(09351-32140)Oil Seal ReplacerOIL PUMP ASSY(U151E/U151F)
09387-00020Direct Clutch WrenchAUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
FORWARD CLUTCH
ASSY(U151E/U151F)
DIRECT CLUTCH
ASSY(U151E/U151F)
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02-2
- PREPARATIONAUTOMATIC TRANSMISSION / TRANS
11 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
09387-00030Counter Drive Gear Holding ToolAUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
09387-00041Bearing Puller AssemblyAUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
(09387-01010)Claw No.1AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
(09387-01021)Claw No.2AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
(09387-01030)PinAUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
(09387-01040)Bearing Puller BodyAUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
09387-00050Under Drive Gear PullerUNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
09387-00060Second Brake WrenchSECOND BRAKE PISTON
ASSY(U151E/U151F)
09387-00070First & Reverse Brake WrenchAUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
09387-00080Counter Drive Gear Nut WrenchAUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
09502-12010Differential Bearing ReplacerUNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
09506-35010Differential Drive Pinion Rear
Bearing ReplacerUNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
09514-3501 1Rear Wheel Bearing PullerAUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
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- PREPARATIONAUTOMATIC TRANSMISSION / TRANS
02-3
12 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
09527-1701 1Rear Axle Shaft Bearing RemoverAUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)
09550-60010Differential Side Bearing
ReplacerFRONT DIFFERENTIAL
ASSY(U151E)
(09951-00490)Replacer 49FRONT DIFFERENTIAL
ASSY(U151E)
09564-3201 1Differential Preload AdaptorFRONT DIFFERENTIAL
ASSY(U151E)
FRONT DIFFERENTIAL
ASSY(U151F)
09608-10010Steering Knuckle Oil Seal
ReplacerFRONT DIFFERENTIAL
ASSY(U151E)
FRONT DIFFERENTIAL
ASSY(U151F)
09649-17010Steering Knuckle ToolAUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)
09710-30050Suspension Arm Bushing ReplacerFRONT DIFFERENTIAL
ASSY(U151E)
09726-40010Lower Control Shaft Bearing
ReplacerUNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
09930-00010Drive Shaft Nut ChiselUNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
(09931-00010)HandleUNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
(09931-00020)Nut ChiselUNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
09950-00020Bearing RemoverFRONT DIFFERENTIAL
ASSY(U151E)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
UNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)